THERMOPLASTIC FILM COMPRISING A FINE POWDER OF A NATURAL ORGANIC SUBSTANCE

Abstract: An ultrafine silk fibroin powder contained in the invention product containing fine powder of natural organic substance is produced by a process comprising the step 1 of pulverizing silk fibroin into a coarse powder by a dry mechanical pulverizing means, the step 2 of pulverizing the coarse powder thus obtained into a fine powder by a dry mechanical pulverizing means, and the step 3 of pulverizing the fine powder thus obtained into an ultrafine powder having an average particle diameter of 10 µm or less by a dry mechanical pulverizing means, while treating the fibroin powder to assume the β-arrangement in or after at least one of the steps 1 to 3. Examples of the title product include film, sheet, coating material and fiber treatment.

Description: This invention relates to a method for producing a substance including natural organic substance fine powder such as a silk fine powder, and can be used in plastics film or sheet, coating medium, fiber treatment agents and the like. Prior art thermoplastic films, for instance of olefin type such as polyethylene and polypropylene, are inferior in the moisture absorbing/releasing property and also the anti-condensation property. Further, they are sometimes sticky. Therefore, they have been inferior in their overall character. The thermoplastics film which additionally includes the waxing compound is apt to be poor in drape and does not show good results in moisture permeation property, moisture absorption-and-discharge property and condensation inhibition property. According to the inventions disclosed in Japanese Patent Laid-Open Publication No. 3-195800 and also Japanese Patent Laid-Open Publication No. 1-293142, there are attempts to overcome the above drawbacks by incorporating skin particles or silk particles. The particles of these natural organic materials, however, have a great water content, and therefore its dispersion is inferior. In addition, the natural organic material powder and the plastics are subject to hydrolysis due to their water content, thus posing problems in the stability during film formation (such as generation of gum or bubbles) to disable continuous production. Further, the overall character, moisture absorbing/releasing property, moisture permeability and anti-condensation property are unsatisfactory, and satisfactory effects of incorporating the above power additives have not been obtained. A first object of the invention, accordingly, is to provide thermoplastic film and laminate which are excellent in the overall character, moisture absorbing/releasing property, moisture permeability, anti-condensation property, anti-blocking property, etc. A second object of the invention is to provide a method of manufacturing the thermoplastic film as noted above. According to a first aspect of the present invention, a thermoplastic film comprising a thermoplastic resin containing a natural organic substance fine powder which has an average particle size of at most 30µm and a water content of 10wt% or below, and which is selected from the group consisting of powdered silk, powdered cellulose, powdered wool and powdered chitin and a thermoplastic resin containing no natural organic substance fine powder wherein the thermoplastic resin is selected from the group consisting of vinyl chloride resins, polystryrene, acrylic resins, polyethylene, polypropylene, fluoride resins, polyamide resins polycarbonate, and thermoplastic elastomers of urethane type, ester type, olefin type. The natural organic substance fine powder is present in an amount from 1 to 40wt% of the film wherein the film is formed by one of an inflation method, T-die extrusion method and calendering method, and wherein the film also contains 5wt% or below of a heat stabilizer. If the average particle size of the natural organic substance fine powder exceeds 30µm, the obtained film is poor in drape (rough touch) and sometimes has pinholes unexpectedly in its producing procedure. If the content of the fine powder of natural organic material is less then 1wt%, it is difficult to obtain such powder incorporation effects as moisture absorbing/releasing property, moisture permeability, condensation suppression property, etc. In addition, with polyurethane or like plastic material subject to blocking, during the film manufacture the blocking takes place to deteriorate the processibility. If more than 40wt%, the contained fine powders are condensed to one another to worsen an appearance and drape of the produced film and also to make a forming stability worse. Accordingly, the recommended percentage for the natural organic substance fine powder is set at a range of from 5 to 15wt%. Typical examples of the thermoplastic material are vinyl chloride resins, polystyrene, acrylic resins (e.g., AS, ABS, etc.), polyethylene, polypropylene, fluoride resins, polyamide resins, polycarbonate, and thermoplastic elastomers of urethane type, ester type, olefin type, etc. The natural organic substance fine powder is at least one member selected from the group of powdered silk, powdered cellulose, powdered wool, and powdered chitin which should be mixed with the thermoplastics. The natural organic material fine powder has to be dried before it is incorporated. Specifically, before its use the fine natural organic material powder is dried at 50 to 200°C for 0.5 to 30 hours, preferably at 100 to 150°C for 2 to 16 hours, to reduce the water content to be 10wt% or below. If the water content exceeds 10wt%, bubbles may be formed during film formation or compound formation, or gum may be generated in a short period of time. At any rate, the stability is deteriorated. Further, because of great water content, the dispersion of the powder in the resin is inferior, thus resulting in inferior overall character of the obtained film. Further, if the water content exceeds 10wt%, hydrolysis is brought about in the fine natural organic material powder and resin (such as polyurethane), thus making it difficult to obtain the effects of incorporating the fine natural organic material powder. Suitably, the water content is 3wt% or below, preferably 1wt% or below. In addition, the thermoplastics film also comprises a heat stabilizer additive. Additional additives may also be included. As an applicable heat stabilizer in the present invention, there are provided phenol antioxidant, amine antioxidant, sulfur antioxidant and phosphorus antioxidant among which the phenol antioxidant is most effective to attain the desired phenomenon. Incidentally, the heat stabilizer is included in the film at or less than 5wt% by weight, preferably at or less than 0.5wt% by weight. According to a second aspect of the present invention, a method of manufacturing thermoplastic film comprises a step of forming a thermoplastic material into a film by inflation molding, T-die molding or calender molding, wherein the thermoplastic material contains from 1 to 40 wt.% of a natural organic substance fine powder selected from the group consisting of silk powder, wool powder, cellulose powder and chitin powder and has a water content of less than 10 wt% and an average particle size of less than 30µm, and wherein a thermoplastic resin is selected from the group consisting of vinyl chloride resins, polystyrene, acrylic resins, polyethylene, polypropylene, fluoride resins, polyamide resins, polycarbonate, and thermoplastic elastomers of urethane type, ester type, olefin type, and wherein the film also contains 5wt% or below of a heat stabilizer. The thermoplastics having a large moisture absorption property should maintain the water content therein at most 3wt% by weight before being used as material, preferably lower than 1wt% by weight through a drying process. However, the drying temperature should not be at high degree to prevent blocking, after-yellowing in order not to spoil the property of pellet. It is possible to form a film without kneading the material. However, it is suitable to knead the thermoplastic material containing the fine natural organic material powder before the film formation. A method in order to obtain the above mentioned film in accordance with the present second invention essentially employs a mixture composed of a thermoplastics including the natural organic substance fine powder (hereinafter referred to as "compound") and a simple thermoplastics not including any natural organic substance fine powder so as to be the percentage by weight of the natural organic substance fine powder within from 1 to 40wt%. The mixture of the thermoplastics as compound and the simple thermoplastics can improve the dispersion property of the natural organic substance fine powder contained therein. The compound may be prepared by means of one of a uniaxial extruder, biaxial extruder, Bumbury's mixer, and kneading machine. However, it is generally noted that even if the materials mixed with the thermoplastics and the natural organic substance fine powder is carefully prepared to obtain the well dried compound, the actually obtained and used compound is apt to involve plenty of moisture since the natural organic substance fine powder is naturally rich in moisture absorption. Accordingly, the compound should be dried before being used at the temperature of 50-200°C for 10 minutes-24 hours, preferably at the temperature of 80-135°C for 2-16 hours. When the drying temperature and time will be set lower than the above-mentioned range, it should represent foaming phenomenon and foreign matter, while if it will be carried out higher, the property will be spoiled and the blocking and after-yellowing of pellet will take place. By drying the thermoplastic material containing the fine natural organic material powder, it is possible to reduce the water content to 5wt%, preferably 2wt% or below, more preferably 0.5wt% or below. The well-dried compound is fed into the molding machine carefully not to absorb moisture therein again, for which it should be promptly supplied into a hopper of the molding machine, otherwise the hopper should be provided with any drying machine. Taking for an instance, if there is a possibility that the troublesome moisture absorption will take place after the treatment of drying, the drying machine accompanied to the hopper of the molding machine should run under a condition at the temperature of 50-200°C, preferably 80-135°C. It should be naturally understood that the drying machine can be a hot-air drying machine, vacuum drying machine or dehumidifying drying machine. The produced thermoplastics film in accordance with the present second invention can be naturally used independently and will be also available to be used in public in a laminated product state consisting of other films, sheets and so on. There can be provided the laminated product with plastic, non-woven fabric, cloth, knitting, foam, natural leather or synthetic leather. The method of lamination can be carried out by means of any adhesive agent or a set of dies with heat. Given below are examples of thermoplastic films, laminates and method of the thermoplastic film manufacture embodying the invention. Example 1 Thermoplastic polyurethane is dried at the temperature of 105 °C for four hours, and collagen fine powder (average particle size 5µm) was dried at the temperature of 120°C for eight hours, using the hot-air drying machine for both. Then, materials, which consists of 69.4wt% by weight of dried thermoplastic polyurethane, 30wt% by weight of dried collagen fine powder, and 0.6wt% by weight of phenol antioxidant as heat stabilizer, was kneaded in a biaxial extruding machine and obtained as a compound. The thus-obtained compound was dried at the temperature of 135 °C for six hours, and further mixed with the thermoplastic polyurethane and the dried collagen fine powder. In the mixture, the rate of the dried compound occupies 30wt% by weight and the thermoplastic polyurethane does 70wt% by weight. Further, the mixture was dried by a hot-air drying machine in association to a hopper at the temperature of 135 °C and fed into an inflation apparatus to produce a thermoplastic polyurethane film (thickness 30µm) based on this embodiment. Incidentally, the obtained thermoplastic polyurethane film contains the collagen fine powder by 9wt% by weight. In the manufacturing process, the water content in fine natural organic material powder before compound preparation was determined by drying the powder at 120°C for 4 hours and measuring the resultant weight change. Table 1 represents a result of the occurrence of foams, the time until foreign matter occurs, and anti-blocking performance during this producing steps. Further, the water content in the compound was measured. The results are shown in Table 3. The anti-blocking performance was graded by the easiness of peeling when molded cylindrical films by the inflation apparatus was opened. The legends of "○", "Δ" and "×" represent the different degrees of anti-blocking performance; "○" means satisfactory state, "Δ" means fair state, and "×" means inferior state. Then, the thermoplastic polyurethane film which contained the collagen fine powder, was graded by the degree of drape, and was measured for moisture permeability, condensed amount and moisture absorption and discharge amount. Table 2 represents the results regarding the above-mentioned measurements, wherein the drape, that is touch feeling, softness and so on, is evaluated by ten persons in random. The shown legends in the table represent the different grade of drape; "o ○" means excellent state, "○" means satisfactory state, "Δ" means fair state, and "×" means inferior state. The moisture permeability is measured conforming to Japanese Industrial Standard (JIS) L-1099 A-1. The measurement procedure of moisture absorption and discharge amount will be explained in detail as follows. 1 ○ Selecting a film to be tested having an even thickness entirely by directly measuring the thickness of the film. 2 ○ Cutting out the film to have an area of 12 square centimeters. 3 ○ Putting the cut film on an aluminum plate similar in size by means of adhesive-backed tapes to expose a part portion thereof having an area of 10 square centimeters. 4 ○The thus-obtained sample is left as it is for 12 hours in a first thermostatic and hydrostatic chamber in which the temperature is always kept at the temperature of 23°C and the relative humidity (RH) is also kept constantly at the degree of 30%. 5 ○ Taking out the sample from the first thermostatic and hydrostat chamber to measure and record the instant weight. 6 ○ Putting promptly the sample into a second thermostatic and hydrostat chamber (Temperature=30°C, Relative humidity=80 %). 7 ○ Measuring and recording the weight of the sample every one hour for 4 hours. The gap of the measured weight compared with that in 5 ○ can be of moisture absorption amount. 8 ○ Resetting the sample in the first thermostatic and hydrostat chamber, and measuring and recording the weight of the sample every one hour for 4 hours. The gap of the measured weight compared with the fourth measured weight in 7 ○ can be of moisture discharge amount. The condensed amount is measured by the following order. The measurement is carried out in a laboratory having an atmosphere at the temperature of 23°C and RH 50% and a filter paper soaking up water therein is allocated on a hot plate to generate moisture vapor therefrom. A sample having an area of 10 square centimeters is put on the filter paper to condense the moisture vapor into drops of water thereon. In this process, it should be paid attention not to escape the moisture vapor through an aperture between the filter paper and the sample resulting from carelessness. This state should be maintained for 10 minutes and then the sample is moved out from inside of the laboratory to collect the drops of water by means of an absorbent paper to thereby measure the change of weight of the absorbent paper. The overall evaluation in Table 1 is an overall judgment of the molding stability, overall character, moisture absorbing/releasing property, etc. The double circle mark represents "very good", the circle mark represents "good", the triangle mark represents "usual", and the cross mark represents "bad". Examples 2-4 In these Examples, the amount of powdered collagen to be applied into the film is limitedly changed but others elements are still in the same condition to obtain the respective thermoplastic polyurethane films containing powdered collagen, more particularly, 3wt% by weight in Example 2, 6wt% by weight in Example 3 and 35wt% by weight in Example 4. Example 5 In Example 5, a film was produced in the same way as in Example 1 except for that the fine collagen powder was dried for 3 hours. Example 6 In Example 6, a film was produced in the same way as in Example 1 except for that silk powder with an average particle diameter of 5µm was used in lieu of the fine collagen powder. Example 7 In Example 7, a film was produced in the same way as in Example 1 except for wood powder (i.e., cellulose powder) with an average particle diameter of 8.2µm in lieu of the fine collagen powder. Example 8 In Example 8, a film was produced in the same way as in Example 1 except for that wool powder was used in lieu of the fine collagen powder. Example 9 In Example 9, a film was produced in the same way as in Example 1 except for that chitin powder was used in lieu of the fine collagen powder. Example 10 Fine collagen powder with an average particle diameter of 5µm was dried at 120°C for 8 hours using a hot air drier. Then, 60wt% of chain-like low density polyethylene and 40 wt. % of the fine collagen powder were mixed and. formed into a compound using a Bumbury's mixer. Then, after drying the compound at 110 for 8 hours, 30wt% of the compound and 70 wt. % of chain-like low density polyethylene were mixed to obtain a polyethylene film (30µm thick) in this example by the T-die molding process. This polyethylene film contained 12wt% of fine collagen powder. Example 11 In Example 11, a film was produced in the same way as in Example 10 except for using polypropylene in lieu of the chain-like low density polyethylene. For the films in Examples 2 to 11, as in Example 1, the water content in the fine natural organic material powder prior to the compound preparation was determined, and also a check was made as to whether bubbles were generated during the film formation. Further, of the obtained films the overall character was evaluated, and also the moisture absorbing/releasing property, etc. were measured. The results are shown in Tables 1 and 2. Comparative Example 1 In this comparative example, a film was produced in the same way as in Example 1 except for that the fine collagen powder was not dried. Comparative Examples 2-5 In Comparative example 2, the thermoplastic polyurethane in Example 1 is dried at the temperature of 105°C for four hours and includes 3wt% by weight of the waxing compound as anti-blocking agent additionally so as to produce the thermoplastic polyurethane film. In Comparative Example 3, the thermoplastic polyurethane film is obtained from the thermoplastic polyurethane without the waxing compound used in Comparative Example 2. In Comparative Example 4, the thermoplastic polyurethane film is obtained without the drying process for the compound and the drying process by the drying machine in association to the hopper. The water content in the compound in this process was measured. The results are shown in Table 3. In Comparative Example 5, the phenol antioxidant as heat stabilizer used in Example 1 is not employed. In Comparative Examples 1 to 5, as in Example 1, the water content in the fine natural organic material powder before the compound preparation was measured, and whether bubbles were generated during the film formation was checked. Further, the overall character of the obtained films was evaluated, and the moisture permeability or the like thereof was measured. The results are shown in Tables 1 and 2. In Comparative Example 3, no film could be obtained due to blocking, and therefore the overall character evaluation and measurement of the moisture permeability or the like could not be obtained. As can be seen, the intended film including 45wt% by weight of powdered collagen does not show an admissible forming stability. The produced film including powdered collagen of which average particle size is over 30µm represents pinholes or is poor in molding to stably produce the film. Compound moisture content Example 1 0.1 wt% Com. Example 4 5.3 wt% NOTE: Com. Example=Comparative Example In accordance with Tables 1 and 2, the produced thermoplastics film is composed of from 1 to 40wt% by weight of the natural organic substance fine powder which has an average particle size of at most 30µm and a moisture content of at most 10wt%, so that it is excellent in drape and shows good results in moisture permeation property ,moisture absorption and discharge property and condensation inhibition property. Further, it will be seen that no bubbles are formed during the film formation, gum generation takes place after the lapse of long time, and satisfactory anti-blocking property is obtainable. Meanwhile, from Comparative Example 1, it will be seen that because the water content in the fine natural organic material powder exceeds 10wt%, the dispersion is deteriorated to result in bubble generation during the film formation or reduction of the effect of incorporating the fine natural organic material powder. As can be seen from the thermoplastics film in Comparative Example 2, it can not show fine results in moisture permeation property, moisture absorption and discharge property and condensation inhibition property as those in the embodiment, since the waxing compound was additionally applied on the film as anti-blocking agent. Reviewing the thermoplastics film in Comparative Example 3, it can be noted that there is employed no additional anti-blocking agent, so that the disadvantage because of blocking phenomenon is taking place. From Comparative Example 4, it will be seen that because the compound is not dried, the water content therein is high compared to the case of Example 1, bubble generation takes place during the film formation, and the time until the gum generation is reduced. In Comparative Example 5, the phenol antioxidant of heat stabilizer is not additionally applied, the time until the occurrence of the foreign matter becomes short. Example 12 Fine collagen powder (with an average particle diameter of 5µm) was dried at 120°C for 8 hours using the hot air drier. Then, 80wt% of chain-like low density polyethylene and 20 wt. % of the fine collagen powder were mixed to produce a compound using the Bumbury's mixer. Then, a polyethylene film (30µm thickness) in this example is formed from the compound using the calender molding process. The polyethylene film contained 20wt% of fine collagen powder. As in Example 1, the water content in the fine natural organic material powder before the compound formation was measured, and further the state of dispersion of the fine powder in the film and the overall character thereof were evaluated. The results are shown in Table 4. In the fine powder dispersion state column in Table 4, the double circle mark represents "very satisfactory dispersion state", and the cross mark represents "unsatisfactory dispersion state". Comparative Example 6 In this Comparative Example, a film was produced in the same way as in Example 12 except for that the fine collagen powder was not dried. As in Example 12, the characteristics measurement and evaluation were made. The results are shown in Table 4. Water content of fine powder before compound State of dispersion of fine particles Overall character Overall evaluation Example 12 0.3wt% o ○ o ○ o ○ Com. Ex. 14.1wt% × × × From Table 4, it will be seen that the polyethylene film in Example 12 has satisfactory characteristics because the film uses dry fine collagen powder with less water content although it is formed by the calender molding process. On the other hand, the polyethylene film in Comparative Example 6 has unsatisfactory characteristics because it uses fine collagen powder which is not dried and contains much water. Example 13 A laminate with a thermoplastic layer was produced by bonding the film obtained in Example 1 with a dry laminate urethane type adhesive to a base material which was a woven cloth of blend spun fibers of 50% nylon and 50% ester. Comparative Example 7 A laminate was produced in the method in Example 13 by using the polyurethane film produced in Comparative Example 1. With the laminates in Example 13 and Comparative Example 7, as in Example 1, the character evaluation and the absorbed and released moisture measurements were made. The results are shown in Table 5. Overall character Moisture absorption and releasing (g/m2) Overall evaluation Absorption Releasing Example 13 o ○ 22.0 21.9 o ○ Com. Ex. 7 × 12.0 11.5 × From Table 5, it will be seen that the laminate in Example 13 has satisfactory overall character and moisture absorbing/releasing property because it has its one layer the film obtained in Example 1. On the other hand, the laminate in Comparative Example 7 has unsatisfactory overall character and moisture absorbing/releasing property because it has as its one layer the film obtained in Comparative Example 1. Industrial Utility The invention, owing to the incorporation of fine silk powder or like fine natural organic material powder, is excellent in the moisture absorbing/releasing property, moisture permeability and touch sense, and is particularly suitable for application to plastic films and sheets, various moldings, paints, fiber treating materials, etc. which are frequently touched by the hand.

Claims: A thermoplastic film comprising (i) a thermoplastic resin containing a natural organic substance fine powder which has an average particle size of at most 30µm and a water content of 10 wt% or below, and which is selected from the group consisting of powdered silk, powdered cellulose, powdered wool and powdered chitin, and (ii) a thermoplastic resin containing no natural organic substance fine powder, wherein the thermoplastic resin is selected from the group consisting of vinyl chloride resins, polystyrene, acrylic resins, polyethylene, polypropylene, fluoride resins, polyamide resins, polycarbonate, and thermoplastic elastomers of urethane type, ester type, or olefin type; the natural organic substance fine powder is present in an amount of from 1 to 40 wt% of the film; the film is formed by one of an inflation method, T-die extrusion method and calendering method; and the film also contains 5wt% or below of a heat stabilizer. A laminate having the film according to claim 1, as one of a plurality of layers. A laminate according to claim 1, wherein the water content of the thermoplastic material containing the natural organic material fine powder is 5 wt% or below. A laminate according to claim 1, wherein the water content of the natural organic material fine powder is 3 wt% or below. A method of manufacturing a thermoplastic film comprising a step of forming a thermoplastic material into a film by inflation molding, T-die molding or calender molding, wherein the thermoplastic material comprises (i) a thermoplastic resin containing a natural organic substance fine powder selected from the group consisting of silk powder, wool powder, cellulose powder and chitin powder and has a water content of less than 10 wt% and an average particle size of less than 30µm, and (ii) a thermoplastic resin containing no natural organic substance fine powder, wherein the thermoplastic resin is selected from the group consisting of vinyl chloride resins, polystyrene, acrylic resins, polyethylene, polypropylene, fluoride resins, polyamide resins, polycarbonate, and thermoplastic elastomers of urethane type, ester type or olefin type; the natural organic substance fine powder is present in an amount of from 1 to 40wt% of the film; and wherein the film also contains 5wt% or below of a heat stabilizer. A method of manufacturing a thermoplastic film according to claim 5, wherein the film is formed by setting the water content of the thermoplastic material containing the natural organic material fine powder to 5 wt% or below. A method of manufacturing a thermoplastic film according to claim 5, wherein the water content of the natural organic material fine powder is 3 wt% or below.

Inventors: FUKATSU FUMIOKI, KUSAMOTO NOBUO, MIKAMI SATOSHI, OHYAMA SHIGERU, SANO MASAHIRO, SASAKI NOBUTAKA, UBARA ATSUHIKO, YASUE TAKAHARU, FUKATSU, FUMIOKI, KUSAMOTO, NOBUO, MIKAMI, SATOSHI, OHYAMA, SHIGERU, SANO, MASAHIRO, SASAKI, NOBUTAKA, UBARA, ATSUHIKO, YASUE, TAKAHARU
Applicants: IDEMITSU PETROCHEMICAL CO, IDEMITSU PETROCHEMICAL CO. LTD.
Application year: 1994
Main classification: C08J5
IPC codes: C08L101, C08J5, C08L5, C08J3, B32B5, C08L1, C08L89, C09D7